DC S-DIAS Axis Module

DC 061-1 S-DIAS Axis Module Date of creation: 26.07.2016 Version date: 29.08.2018 Article number: 20-014-061-1E

Publisher: SIGMATEK GmbH & Co KG A-5112 Lamprechtshausen Tel.: +43/6274/4321 Fax: +43/6274/4321-18 Email: office@sigmatek.at WWW.SIGMATEK-AUTOMATION.COM Copyright 2016 SIGMATEK GmbH & Co KG Translation from German All rights reserved. No part of this work may be reproduced, edited using an electronic system, duplicated or distributed in any form (print, photocopy, microfilm or in any other process) without the express permission. We reserve the right to make changes in the content without notice. The SIGMATEK GmbH & Co KG is not responsible for technical or printing errors in the handbook and assumes no responsibility for damages that occur through use of this handbook.

S-DIAS AXIS MODULE DC 061-1 S-DIAS Axis Module DC 061-1 with 1 motor output stage 1 resolver input 1 holding brake The S-DIAS DC 061-1 axis module is used to control a brushless DC motor with a 48-Volt supply voltage and phase current of up to 6 A. A Resolver input is available for position feedback. A 24 V output for connecting a holding brake is provided. External Regen brake can also be connected. 29.08.2018 Page 1

DC 061-1 S-DIAS AXIS MODULE Contents 1 Technical Data... 4 1.1 Motor Driver Specifications... 4 1.2 Resolver Specifications... 4 1.3 Enable Inputs Specifications... 4 1.4 Holding Brake Specifications... 5 1.5 Regen Brake Specifications... 5 1.6 Electrical Requirements... 5 1.7 Miscellaneous... 8 1.8 Environmental Conditions... 8 2 Mechanical Dimensions... 9 3 Connector Layout...10 3.1 Baumüller... 10 3.2 Kollmorgen... 11 3.3 Status LEDs... 12 3.4 Applicable Connectors... 13 3.5 Label Field... 15 4 Wiring...16 4.1 Wiring Example... 16 4.2 Wiring AKM Motors... 17 4.2.1 Wiring AKM Motors with Standard Round Connectors... 18 4.2.2 Wiring AKM Motors with Molex Connectors... 19 Page 2 29.08.2018

S-DIAS AXIS MODULE DC 061-1 5 Motor Overload Protection... 20 6 Safety... 20 6.1 Functional Safety Standards... 20 6.2 Safety-Relevant Parameters... 20 7 Additional Safety Information... 21 7.1 STO... 22 7.2 Function... 23 7.3 Function Test... 23 8 Wiring Examples... 24 8.1 Performance Level e, category 4 or SIL 3 Safety SPS... 24 8.2 Performance Level e, category 3 & SIL 3 Safety SPS... 26 8.3 Performance Level e, category 4 or SIL 3 Conventional... 28 8.4 Performance Level d, category 2 or SIL 2 Conventional... 30 9 Mounting... 32 29.08.2018 Page 3

DC 061-1 S-DIAS AXIS MODULE 1 Technical Data 1.1 Motor Driver Specifications Type Operating voltage Maximum continuous current Maximum peak current (10 sec) Overload protection brushless, 4-quadrant regulator with position setting +18-55 V 6 A 15 A short circuit cutoff temperature monitor I2T monitor over and under voltage monitor 1.2 Resolver Specifications Type Resolution Output voltage (EXC) Maximum output current (EXC) Output frequency Input voltage resolver 12-bit typically 7 Vrms 200 ma 4 khz typically 3.5 Vrms Resolver transfer ratio 0.5 1.3 Enable Inputs Specifications Number 2 Input voltage Input voltage range 24 V 18-24 V Signal level low: < 5 V high: > 15 V Switching threshold Input current Input delay typically 11 V 3 ma at 24 V typically 0.5 ms Page 4 29.08.2018

S-DIAS AXIS MODULE DC 061-1 1.4 Holding Brake Specifications Output voltage Maximum continuous current Short-circuit protection 24 V 500 ma yes 1.5 Regen Brake Specifications Type Output external power resistor GND switching Maximum current 10 A (1) Lowest possible resistance 6 Ω (2) Short-circuit protection Threshold regen braking on/off yes 60 V/55 V (1) Regen braking must be dimensioned according to the application. For most applications, a 10 Ω/50 W resistor is sufficient. If multiple DC 061-1s are driven with one intermediate circuit supply, it is possible to equip only one module with regen braking. The recommended regen resistor is available at SIGMATEK under the article number 20-014-061-Z1. (2) The resistor must be dimensioned with regard to its maximum power dissipation in accordance with the braking power occurring in the application. However, the permissible short-term power must be at least P=U2/R, i.e. 602/R. 1.6 Electrical Requirements Power supply +24 V +18-30 V, Class 2 Current consumption of the +24 V supply load-dependent (holding brake) Supply voltage motor +18-55 V (2) Switching threshold for motor voltage monitor minimum 18 V maximum 65 V Current consumption of motor supply Voltage supply from S-DIAS bus Current consumption on the S-DIAS bus (+24 V supply) typically 70 ma load-dependent (motor) +24 V maximum 80 ma (2) The motor supply must be connected with an intermediate circuit capacitance appropriate for the application (at least 2000 µf/100 V). 29.08.2018 Page 5

DC 061-1 S-DIAS AXIS MODULE For USA and Canada: The supply must be limited to: a) max. 5 A at voltages from 0-20 V DC, or b) 100 W at voltages from 20-60 V DC The limiting component (e.g. transformer, power supply or fuse) must be certified by an NRTL (Nationally Recognized Testing Laboratory). Pour les États-Unis et le Canada: L alimentation doit être limitée à: a) max. 5 A pour des tensions de 0-20 V DC, ou b) 100 W pour des tensions de 20-60 V DC Le composant imposant la limite (par exemple, transformateur, alimentation électrique ou fusible) doit être certifié par un NRTL (National Recognized Testing Laboratory, par exemple, UL). Servo Motor Braking When applying the brake in a servo motor, a generative process can occur whereby the kinetic energy of the motor is converted into electrical energy. The energy of the motor is thereby fed back into the supply of the servo motor output stage; this then increases the supply voltage. It should be noted that a regenerative voltage of 65 V at the motor supply connection is not exceeded! The external capacity of the motor supply is may be needed. If the capacitors in the power supply are insufficient, a regen resistor, which converts the excess energy into heat must be connected to the servo motor output stage. When selecting the power supply, it is important to ensure that it is appropriately feedback-resistant up to the maximum regenerative voltage that occurs. Use 75 C wires only! Motor overtemperature sensing is not provided by the drive. Incorrectly set parameter or incorrect wiring can lead to destruction of the motor. In particular, motor currents and the I 2 T settings (A-I2TT, A-I2TERR) must be monitored. Only motors in a star connection can be used. Page 6 29.08.2018

S-DIAS AXIS MODULE DC 061-1 29.08.2018 Page 7

DC 061-1 S-DIAS AXIS MODULE 1.7 Miscellaneous Article number 20-014-061-1 Hardware version 1.x Standard Approbations UL 508C (E336350) UL, cul, CE 1.8 Environmental Conditions Storage temperature -20... +85 C Environmental temperature 0... +50 C Humidity 0-95 %, non-condensing Operating conditions Pollution degree 2 Indoor use altitude up to 2000 m EMC resistance EMC noise generation in accordance with EN 61000-6-2 (industrial area) in accordance with EN 61000-6-4 (industrial area) Vibration resistance EN 60068-2-6 3.5 mm from 5-8.4 Hz 1 g from 8.4-150 Hz 5 g from 8-150 Hz Shock resistance EN 60068-2-27 15 g Protection type EN 60529 IP20 Page 8 29.08.2018

S-DIAS AXIS MODULE DC 061-1 2 Mechanical Dimensions 29.08.2018 Page 9

DC 061-1 S-DIAS AXIS MODULE 3 Connector Layout 3.1 Baumüller * Both holding brake outputs (BR) are internally connected in parallel. Therewith, the holding brake can be wired optionally to X3 (pin 7-pin 8) or X4 (pin 3-GND). With the layout, and M-ROFF of 270 results. Page 10 29.08.2018

S-DIAS AXIS MODULE DC 061-1 3.2 Kollmorgen *Both holding brake outputs (BR) are internally connected in parallel. The holding brake can therewith be optionally connected to X3 (pin 7- Pin 8) or X4 (pin 3-GND). 29.08.2018 Page 11

DC 061-1 S-DIAS AXIS MODULE 3.3 Status LEDs Module Status green ON module active OFF BLINKING (5 Hz) no supply available no communication User yellow ON can be set from the application OFF BLINKING (2 Hz) (e.g. the module LED can be set to blinking through the visualization so that the module is easily found in the control cabinet) BLINKING (4 Hz) Motor Error red BLINKING motor output stage error OFF normal operation Motor DC OK green OFF no motor supply voltage BLINKING ON power applied, but motor inactive power applied and motor active Enable 1 green ON enable 1 high OFF enable 1 low Enable 2 green ON enable 2 high OFF enable 2 low Holding brake yellow ON output active OFF output inactive DC OK green ON 24 V supply OK OFF BLINKING 24 V missing or voltage too low 24 voltage supply too high Page 12 29.08.2018

S-DIAS AXIS MODULE DC 061-1 3.4 Applicable Connectors X1, X2: Weidmüller socket connector with spring terminal (included in delivery) X3, X4: Phoenix connectors with spring terminals (included in delivery) The spring terminals are suitable connecting ultrasonically compacted (ultrasonically welded) strands. Connections Weidmüller Plug Connectors: Stripping length/sleeve length: Plug-in direction: 9 mm Conductor cross section, rigid: H05(07) V-U 0.14-1.5 mm 2 Conductor cross section, flexible: H05(07) V-K 0.14-1.5 mm 2 Conductor cross section, ultrasonically compacted 0.14-1.5 mm 2 Conductor cross section AWG/kcmil: 26-16 Conductor cross section flexible, with ferrule without plastic sleeve (DIN 46228-1): Conductor cross section flexible, with ferrule with plastic sleeve (DIN 46228-4): parallel to conductor axis or to PCB 0.25-1.5 mm 2 0.25-1 mm 2 (ground for reducing d2 of the ferrule) Connections Phoenix Plug Connectors: Stripping length/sleeve length: Plug-in direction: 10 mm Conductor cross section, rigid: 0.2-1.5 mm 2 Conductor cross section, flexible: 0.2-1.5 mm 2 Conductor cross section, ultrasonically compacted 0.2-1.5 mm 2 Conductor cross section AWG/kcmil: 24-16 Conductor cross section flexible, with ferrule without plastic sleeve: Conductor cross section flexible, with ferrule with plastic sleeve: parallel to conductor axis or to PCB 0.25-1.5 mm 2 0.25-0.75 mm 2 (ground for reducing d2 of the ferrule) IMPORTANT: The S-DIAS module CANNOT be connected or disconnected while voltage is applied! 29.08.2018 Page 13

DC 061-1 S-DIAS AXIS MODULE IMPORTANT: Le module S-Dias NE PEUT PAS être inséré ou retiré sous tension. Page 14 29.08.2018

S-DIAS AXIS MODULE DC 061-1 3.5 Label Field Manufacturer Type Weidmüller MF 10/5 CABUR MC NE WS Weidmüller article number 1854510000 Compatible printer Type Weidmüller Printjet Advanced 230V Weidmüller article number 1324380000 29.08.2018 Page 15

DC 061-1 S-DIAS AXIS MODULE 4 Wiring 4.1 Wiring Example Page 16 29.08.2018

S-DIAS AXIS MODULE DC 061-1 4.2 Wiring AKM Motors with SIGMATEK resolver and motor cables AKM 29.08.2018 Page 17

DC 061-1 S-DIAS AXIS MODULE 4.2.1 Wiring AKM Motors with Standard Round Connectors With Holding Brake M061E-10-1-015-0-0 M061E-10-1-030-0-0 M061E-10-1-050-0-0 M061E-10-1-100-0-0 Length 15 m 30 m 50 m 100 m Without Holding Brake M061E-10-0-015-0-0 M061E-10-0-030-0-0 M061E-10-0-050-0-0 M061E-10-0-100-0-0 Length 15 m 30 m 50 m 100 m The Shielding/PE connections of the motor cable, as well as the encoder cable shielding must be grounded on the module side via the 6.3 mm blade receptacle provided on the respective cables Page 18 29.08.2018

4.2.2 Wiring AKM Motors with Molex Connectors S-DIAS AXIS MODULE DC 061-1 With Holding Brake M061E-10-1-015-3-0 M061E-10-1-030-3-0 M061E-10-1-050-3-0 M061E-10-1-100-3-0 Length 15 m 30 m 50 m 100 m Without Holding Brake M061E-10-0-015-3-0 M061E-10-0-030-3-0 M061E-10-0-050-3-0 M061E-10-0-100-3-0 Length 15 m 30 m 50 m 100 m The Shielding/PE connections of the motor cable, as well as the encoder cable shielding must be grounded via the 6.3 mm blade receptacle provided on the respective cables. With increased interference, it may be necessary to also connect the motor and encoder cable on the motor side. If the Molex connector could experience strain during use, it must be equipped with proper strain relief directly before and after the connector. 29.08.2018 Page 19

DC 061-1 S-DIAS AXIS MODULE 5 Motor Overload Protection Equipment does not incorporate motor overload protection. External or remote overload protection in accordance with National Electrical Code and any additional local codes must be provided in the field. 6 Safety 6.1 Functional Safety Standards - EN 62061 SIL 3 or SILCL 3 - EN ISO 13849-1 PL e/cat. 4 6.2 Safety-Relevant Parameters Parameter PFHd MTTFd Safety function STO 1.50E-11 (1/h) 8949 years DC 99.94 % Page 20 29.08.2018

S-DIAS AXIS MODULE DC 061-1 7 Additional Safety Information The Safety function STO is an integrated part of the DC 061-1. It meets all necessary requirements for safe operation in SIL 3 according to EN 62061 and in compliance with PL e. Cat. 4 in accordance with EN ISO 13849-1. Safety modules can only be powered by supplies that meet the requirements for PELV in compliance with EN60294. Installation, mounting, programming, initial start-up, operation, maintenance and discarding of safety modules can only be performed by qualified personnel. Qualified personnel in this context are people who have completed training or have trained under supervision of qualified personnel and have been authorized to operate and maintain safety-related equipment, systems and facilities in compliance with the strict guidelines and standards of safety technology. For your own safety and the safety of others, use safety modules for their designated purpose. Correct EMC installation is also included under designated use. Non-designated use consists of Any changes made to the Safety modules or the use of damaged modules The use of the Safety modules outside of technical margins described in these operating instructions The use of the Safety modules outside of the technical data described in these operating instructions (see the "Technical data" sections of the respective product) In addition, observe the warnings in the other sections of these instructions. These instructions are visibly emphasized by symbols. Only qualified personnel are authorized to install the "safe restart" STO (Safe Torque off) and set the parameters. All control devices (switches, relays, PLC, etc.) and the control closet must meet the requirements for EN 13849. This consists of: - Door switches, etc. with at least IP54 protection - Control cabinet with at least IP54 protection The proper cables and end-sleeves must be used All cables that affect safety (e.g. control cables for the ENABLE 1 and ENABLE 2 inputs) must be laid in a cable duct outside of the control cabinet. Short and cross circuits have to be avoided. See EN ISO 13849 29.08.2018 Page 21

DC 061-1 S-DIAS AXIS MODULE When using the SS1 (Safe Stop 1) safety function, the typical turn-off delay is 0.5 seconds. Subsequent actions that require the STO (Safe Torque Off) function (i.e. manual access to the machine), can only be released after 1 second. If external forces influence axes that are used with the STO safety function (e.g. hanging load), additional measures must be taken (such as an electromagnetic double-surface spring brake, instead of a permanent magnet brake). Failure to follow the above safety measures can lead to severe injuries. The main power supply for the servo amplifier must be disconnected using the main switch for the following instances: Cleaning, maintenance or repairs Extended still-stand periods Failure to follow the above safety measures can lead to severe injuries. 7.1 STO The DC 061-1 supports the safety functions STO (Safe Torque Off), and meets the requirements for Category 4 Performance Level "e" according to EN ISO 13849-1 and SIL3 according to EN 62061. For his purpose, the servo amplifier has two safe inputs ENABLE 1 and ENABLE 2. The stop brake control is not a component of the safety function. If a safe shutdown of the stop brake is required, the +24 V-BR brake supply must also be shut down externally. For the 24 V supply, only PELV/SELV can be used. Page 22 29.08.2018

S-DIAS AXIS MODULE DC 061-1 7.2 Function The safety functions in the DC 061-1 are controlled over two digital inputs. The following table shows the status that the ENABLE 1 and ENABLE 2 inputs must assume to enable normal operation or trigger the safety function. Input Status Description ENABLE 1 ENABLE 2 Open Open Safe status of Open Low the drive system Low Low Low High Open Low High Low High High Drive system ready If the ENABLE 1 and ENABLE 2 are changed from any status to the "Drive Ready" status, the servo amplifier is not immediately enabled. In order to set the system to the status Drive system ready, a change from Low - Low to High - High has to be executed. 7.3 Function Test The safety function test is required to ensure correct operation. The entire safety circuit must be tested for full functionality. Tests must be performed at the following times: After installation In regular intervals, or at least once a year. If the function test results in an invalid machine status, the error must be found and corrected before the safety function is retested. If the error reoccurs during the function test, the machine can no longer be operated. Failure to follow the above safety measures can lead to severe injuries and damage. 29.08.2018 Page 23

DC 061-1 S-DIAS AXIS MODULE 8 Wiring Examples In the following sub chapters, wiring examples are provided. It must be ensured that all constructive measures etc. are complied with and applied in order to fulfill the requirements of the category used. 8.1 Performance Level e, category 4 or SIL 3 Safety SPS To meet the requirements of category 4, performance Level "e" for EN ISO 13849-1 and SIL 3 according to EN 62061, two error-proof output of a Safety PLC must be used. Crosscircuit detection between the two lines via the output tests of the STO 081 is hereby possible. Page 24 29.08.2018

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DC 061-1 S-DIAS AXIS MODULE 8.2 Performance Level e, category 3 & SIL 3 Safety SPS To meet the requirements of safety category 3, performance level "e" for EN 13849-1 and SIL 3 according to EN 62061, an error-proof output of a safety PLC must be used. The reason of category 3 here, is that cross-circuit detection between the two lines is not possible. Page 26 29.08.2018

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DC 061-1 S-DIAS AXIS MODULE 8.3 Performance Level e, category 4 or SIL 3 Conventional To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and SIL 3 according to EN 62061, the placement of the lines must comply with EN ISO 13849-2, table D.4 (separate placement, prohibiting of error via short circuits between wires) as cross-circuit detection is not possible here. Page 28 29.08.2018

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DC 061-1 S-DIAS AXIS MODULE 8.4 Performance Level d, category 2 or SIL 2 Conventional This involves 1-channel wiring, whereby the Enable inputs are tested separately. Here, no cross-circuit detection is possible. Page 30 29.08.2018

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DC 061-1 S-DIAS AXIS MODULE 9 Mounting The S-DIAS modules are designed for installation into the control cabinet. To mount the modules a DIN-rail is required. The DIN rail must establish a conductive connection with the back wall of the control cabinet. The individual S-DIAS modules are mounted on the DIN rail as a block and secured with latches. The modules must be mounted horizontally (module label up) with sufficient clearance between the ventilation slots of the S-DIAS module blocks and nearby components and/or the control cabinet wall. This is necessary for optimal cooling and air circulation, so that proper function up to the maximum operating temperature is ensured. Page 32 29.08.2018

S-DIAS AXIS MODULE DC 061-1 Recommended minimum distances of the S-DIAS modules to the surrounding components or control cabinet wall: a, b, c distances in mm (inches) 29.08.2018 Page 33

DC 061-1 S-DIAS AXIS MODULE Documentation Changes Change date Affected page(s) Chapter Note 06.02.2017 6 1.6 Electrical Requirements Added warning 19.05.2017 14 4.1 Wiring example Diagram replaced 17.08.2017 8 13 18.10.2017 14 29 1.8 Environmental Conditions 3.4 Applicable Connectors 3.5 Label Field 9 Mounting Added operating conditions Added sleeve length Added info regarding ultrasonically welded strands Added chapter Graphic replaced 08.11.2017 16 4.2 Wiring AKM Motors Chapter added 15.12.2017 6 1.6 Electrical Requirements Note Servo Motor Braking added 31.01.2018 13 3.4 Applicable Connectors Connections Weidmüller added 04.04.2018 5 1.5 Regen Brake Specifications Lowest possible resistance added 18.06.2018 7 1.6 Electrical Requirements Notes updated 13.08.2018 17 18 4.2.1 Wiring AKM Motors with Standard Round Connectors 4.2.2 Wiring AKM Motors with Molex Connectors Chapter added 29.08.2018 17 4.2 Wiring AKM Motors Graphic corrected Page 34 29.08.2018